Shear strength and temperature distribution model of friction spot lap joint of high density polyethylene with aluminum alloy 7075

Abdullah, Isam Tareq; Hussein, Sabah Khammass

doi:10.1108/ijsi-05-2018-0025

Cited by 9 publications

(6 citation statements)

References 25 publications

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“…The inner surfaces of the aluminium specimens indicated that the joining process was achieved by mixing the molten polymer with the aluminium fragments. Here, two types of mixing were observed: full and partial mixing (Abdullah and Hussein, 2019). A homogenous mixing of the molten polymer with fragments gave higher joint strength in specimens 1, 6, 11, 16 and 21.…”

Section: Resultsmentioning

confidence: 99%

“…Lambiase and Genna (2018) joined AA5053 with PVC using the laser-assisted joining technique with average shear strength efficiency of 71 per cent. Abdullah and Hussein (2019) used a joining mechanism based on re-filling the pre-holed AA7075 specimen with the molten HDPE via the friction spot technique. The results indicated that the plunging depth exhibited the highest effect on the heat input, and the joined samples failed, with shearing of the polymer layers without pullout.…”

Section: Introductionmentioning

confidence: 99%

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Joining of AA6061 to polyvinyl chloride via hot extrusion

Abdullah

Hussein

2019

IJSI

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Purpose The purpose of this paper is to join aluminium alloy AA6061 with polyvinyl chloride (PVC) sheets using the friction spot technique. Design/methodology/approach The AA6061 specimen was drilled with a semi-conical hole and put over the PVC specimen with a lap configuration. A friction spot technique was used to generate the required heat to melt and extrude the PVC through the aluminium hole. In this study, three process parameters were used: time, plunging depth and rotating speed of the tool. Thermal finite element model was built to analyse the process temperature. Effect of the process parameters on the joint shear strength and temperature was analysed using the design of experiments method. The microstructure investigation of the joint cross section was examined. Findings The input heat melted and extruded the polymer into the aluminium hole with the aid of tool pressure. A mechanical interlock was observed at the interface line between the polymer and aluminium. The scattered aluminium fragments into the molten polymer increased the shear strength of the joint. The hole diameter exhibited the highest effect on the joint strength compared with the other parameters. Specimen of minimum hole diameter recorded the maximum shear strength of 224 MPa. The proposed model gave a good agreement with the experimental data. Originality/value For the first time, the PVC was joined with AA6061 by the hot extrusion using the friction spot technique. The shear strength of joint reached 7.5 times of the base material (PVC).

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Section: Resultsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Joining of AA6061 to polyvinyl chloride via hot extrusion

Abdullah

Hussein

2019

IJSI

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“…Temperature distribution of friction spot joint for the sample at t = 1 s and t = 10 s. Reprinted by permission from Emerald Publishing Limited. 86 …”

Section: Finite Elemental Studies On Welding Techniques For Aluminium...mentioning

confidence: 99%

Review on the advancements and relevance of emerging joining techniques for aluminium to polymers/carbon fibre-reinforced polymer lightweight hybrid structures

Adarsh

Natarajan

2022

Proceedings of the Institution of Mechanical Engineers, Part L:

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The demand for higher fuel efficiency and low fuel pollution rates leads to the development of lightweight hybrid structures. The predominant aim is to develop innovative light products with extreme versatility with bionomic and economic balance. Lightweight materials in the structures have successfully solved these problems in many industries, especially automobiles and aerospace. There is an emerging scope in producing automotive components by joining Al and Mg-based alloys with materials such as thermoplastics, ceramics and fibre-reinforced composites. Developing hybrid structures by employing metal–polymer joining is still a significant challenge. There are as many joining techniques available for joining metal with a polymer. Owing to certain drawbacks, some methods are ineffective, such as high processing time for adhesive bonding and mechanical fastening due to increased weight. The friction-based welding technique benefits hybrid joining due to its low heat-affected zone with less metallurgical damages. The study provides an overview of many emerging technologies for joining aluminium to thermoplastic/carbon fibre-reinforced polymer for lightweight structures. The paper compares different joint configurations and the effect of process variables on the microstructural and mechanical properties of hybrid joints. In addition, attempts are made to comprehend contemporary developments in the finite element simulation studies of hybrid structures. The paper also highlights recently developed strategies and gaps in areas where future studies might be focussed. Thus, the paper gives an overview of the advancements and relevance of the emerging joining technique for aluminium to polymers/carbon fibre-reinforced polymer hybrid structures.

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“…The rotating tool remains in touch with the aluminium specimen for a specific pre-heating time. During this step, the rotating friction between the two surfaces generates a frictional heat that increases gradually depending on the pre-heating time (Abdullah and Hussein, 2019). The amount of the frictional heat depends on the coefficient of friction between the two surfaces (Zhang et al , 2018).…”

Section: The Process Detailsmentioning

confidence: 99%

“…To achieve the joining process, three processing parameters were used: pre-heating time, rotating speed and plunging depth of the tool. The first two parameters determine the amount of input heat through the specimens (Abdullah and Hussein, 2019), which softens the aluminium during the process. The plunging depth of tool determines the incremental increase in the input heat and extrudes the softening aluminium through the steel hole with the aid of the applied load from the rotating tool.…”

Section: The Process Detailsmentioning

confidence: 99%

Joining of aluminium alloy to pre-holed carbon steel by aluminium extrusion using friction spot method

Abdullah

Hussein

2019

IJSI

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Purpose The purpose of this paper is to join sheets of an aluminium alloy together with pre-holed carbon steel via friction spot technique. Design/methodology/approach An AISI 1006 steel sheet was a pre-holed with a 4.8 mm diameter and put under AA5052 sheet with a lap joint configuration. The joining process was carried out by extruding the aluminium through the steel hole using a rotating tool of 10 mm diameter. Furthermore, three process parameters (pre-heating time, rotating speed and plunging depth of the tool) with three values for each parameter were used to study their effects on the joints quality. In order to join samples, nine experiments were designed according to a Taguchi method. Shear strength, microstructure and X-ray diffraction tests of the joint were carried out. Findings The joining mechanism occurred by a mechanical interlock of the extruded aluminium with the inner surface of the steel hole. The tool plunging depth had a significant effect on the shear strength of the joint. The shear strength of two joints exceeded the shear strength of the wrought material (AA5052). All samples failed with two modes: pull-out and shearing of the extruded aluminium. Originality/value For the first time, the extrusion technique was used to join AA5052 sheet together with pre-holed carbon steel, with a perfect joint efficiency.

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Shear strength and temperature distribution model of friction spot lap joint of high density polyethylene with aluminum alloy 7075

Cited by 9 publications

References 25 publications

Joining of AA6061 to polyvinyl chloride via hot extrusion

Joining of AA6061 to polyvinyl chloride via hot extrusion

Review on the advancements and relevance of emerging joining techniques for aluminium to polymers/carbon fibre-reinforced polymer lightweight hybrid structures

Joining of aluminium alloy to pre-holed carbon steel by aluminium extrusion using friction spot method

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